Injection molding method

ABSTRACT

An injection-molding method includes providing an extruding system configured to produce a mixture, a first discharging channel including a first outlet, a second discharging channel including a second outlet, and a molding device including a space and first and second feeding ports communicable with the space and respectively engageable with the first and second outlets; engaging the first outlet with the first feeding port; engaging the second outlet with the second feeding port; injecting the mixture through the first outlet and the first feeding port; and injecting the mixture through the second outlet and the second feeding port.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional application of a U.S. patentapplication entitled INJECTION MOLDING SYSTEM, Ser. No. 16/857,092,filed Apr. 23, 2020, which claims priority of U.S. provisionalapplication Ser. No. 62/915,287 filed on Oct. 15, 2019, U.S. provisionalapplication Ser. No. 62/950,454 filed on Dec. 19, 2019.

TECHNICAL FIELD

The present invention is related to an injection-molding system and aninjection-molding method, and, in particular, to an injection-moldingsystem and an injection-molding method for making a foamed article.

BACKGROUND

Foamed polymeric material has many advantages, such as high strength,low weight, impact resistance, thermal insulation, and others. Foamedarticles can be made by injection molding or extrusion molding. Forexample, after the polymeric material is melted and mixed with a blowingagent to form a mixture, a force or pressure is applied to the mixtureto inject or extrude the mixture into a cavity of a mold, and themixture is foamed and cooled in the cavity to form the foamed article.

However, it is necessary to improve the properties of the foamed articlemade by the injection-molding system, such as causing different portionsof the foamed article to have different properties. Therefore, there isa need for improvements to structures of the injection-molding systemand the method for making foamed articles.

BRIEF SUMMARY OF THE INVENTION

One purpose of the present invention is to provide an injection-moldingsystem and a method of injection molding.

According to one embodiment of the present disclosure, aninjection-molding system is disclosed. The injection-molding systemincludes an extruding system, a plurality of discharging channels and amolding device. The extruding system is configured to produce a mixtureof a polymeric material and a blowing agent. Each of the dischargingchannels is communicable with the extruding system, and each of thedischarging channels includes an outlet disposed distal from theextruding system and configured to discharge the mixture. The moldingdevice is configured to receive the mixture from the outlets. Themolding device includes a hollow space, and a plurality of feeding portscommunicable with the hollow space and correspondingly engageable withthe outlets.

According to one embodiment of the present disclosure, a method ofinjection molding is disclosed, The method of injection molding includesproviding an extruding system configured to produce a mixture of apolymeric material and a blowing agent, a first discharging channel, asecond discharging channel, and a molding device including a hollowspace, a first feeding port and a second feeding port, wherein the firstdischarging channel is communicable with the extruding system andincludes a first outlet disposed distal from the extruding system, thesecond discharging channel is communicable with the extruding system andincludes a second outlet disposed distal from the extruding system, andthe first feeding port and the second feeding port are communicable withthe hollow space and engageable with the first outlet and the secondoutlet, respectively. The method of injection molding further includesengaging the first outlet with the first feeding port; engaging thesecond outlet with the second feeding port; injecting a first amount ofthe mixture into the hollow space through the first outlet and the firstfeeding port; and injecting a second amount of the mixture into thehollow space through the second outlet and the second feeding port.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of the present disclosure are best understood from the followingdetailed description when read with the accompanying figures. It shouldbe noted that, in accordance with the standard practice in the industry,various features are not drawn to scale. In fact, the dimensions of thevarious features may be arbitrarily increased or reduced for clarity ofdiscussion.

FIG. 1 is a schematic diagram of an injection-molding system accordingto one embodiment of the present invention.

FIG. 2 is a top cross-sectional view of a molding device in aninjection-molding system according to one embodiment of the presentinvention.

FIG. 3 is a top cross-sectional view of a foamed article formed by aninjection-molding system according to one embodiment of the presentinvention.

FIG. 4 is a cross-sectional view along a line a-a′ of the foamed articleof FIG. 3.

FIGS. 5 to 10 are schematic diagrams of an injection-molding system invarious configurations.

FIGS. 11a to 11c are schematic diagrams of a discharging channel invarious configurations.

FIG. 12 is a schematic diagram of an injection-molding system accordingto one embodiment of the present invention,

FIG. 13 is a schematic diagram of an injection-molding according to oneembodiment of the present invention.

FIG. 14 is a schematic diagram of a part of the injection-molding systemin FIG. 13 according to one embodiment of the present invention.

FIG. 15 is a schematic diagram of a part of the injection-molding systemin FIG. 13 according to one embodiment of the present invention.

FIG. 16 is a schematic diagram of an injection-molding system accordingto one embodiment of the present invention.

FIG. 17 is a top cross-sectional view of a part of an injection-moldingsystem according to one embodiment of the present invention.

FIG. 18 is a schematic cross-sectional view of a part of aninjection-molding system according to one embodiment of the presentinvention.

FIG. 19 is a schematic diagram of a cover in an injection-molding systemaccording to one embodiment of the present invention.

FIG. 20 is a schematic diagram of a cover in an injection-molding systemaccording to one embodiment of the present invention.

FIG. 21 is a schematic diagram of an injection-molding system accordingto one embodiment of the present invention.

FIG. 22 is a flowchart illustrating an injection mo method according toone embodiment of the present invention.

FIGS. 23 to 27 are schematic diagrams illustrating exemplary operationsin a method of injection molding according to one embodiment of thepresent disclosure.

DETAILED DESCRIPTION

The following disclosure provides many different embodiments, orexamples, for implementing different features of the provided subjectmatter. Specific examples of components and arrangements are describedbelow to simplify the present disclosure. These are, of course, merelyexamples and are not intended to be limiting. For example, the formationof a first feature over or on a second feature in the description thatfollows may include embodiments in which the first and second featuresare formed in direct contact, and may also include embodiments in whichadditional features may be formed between the first and second features,such that the first and second features may not be in direct contact. Inaddition, the present disclosure may repeat reference numerals and/orletters in the various examples. This repetition is for the purpose ofsimplicity and clarity and does not in itself dictate a relationshipbetween the various embodiments and/or configurations discussed.

Further, spatially relative terms, such as “beneath,” “below,” “lower,”“above,” “upper” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. The spatiallyrelative terms are intended to encompass different orientations of thedevice in use or operation in addition to the orientation depicted inthe figures. The apparatus may be otherwise oriented (rotated 90 degreesor at other orientations) and the spatially relative descriptors usedherein may likewise be interpreted accordingly.

Notwithstanding that the numerical ranges and parameters setting forththe broad scope of the disclosure are approximations, the numericalvalues set forth in the specific examples are reported as precisely aspossible. Any numerical value, however, inherently contains certainerrors necessarily resulting from the standard deviation found in therespective testing measurements. Also, as used herein, the term “about”generally means within 10%, 5%, 1%, or 0.5% of a given value or range.Alternatively, the term “about” means within an acceptable standarderror of the mean when considered by one of ordinary skill in the art.Other than in the operating/working examples, or unless otherwiseexpressly specified, all of the numerical ranges, amounts, values andpercentages such as those for quantities of materials, durations oftimes, temperatures, operating conditions, ratios of amounts, and thelikes thereof disclosed herein should be understood as modified in allinstances by the term “about.” Accordingly, unless indicated to thecontrary, the numerical parameters set forth in the present disclosureand attached claims are approximations that can vary as desired. At thevery least, each numerical parameter should be construed in light of thenumber of reported significant digits and by applying ordinary roundingtechniques. Ranges can be expressed herein as from one endpoint toanother endpoint or between two endpoints. All ranges disclosed hereinare inclusive of the endpoints, unless specified otherwise.

FIG. 1 is a schematic diagram of an injection-molding system 100according to one embodiment of the present invention. Theinjection-molding system 100 includes an extruding system 10, aplurality of discharging channels 20 a, 20 b, and a molding device 30.The extruding system 10 is configured to produce the mixture of apolymeric material and a blowing agent, and configured to inject themixture into the discharging channels 20 a, 20 b. The extruding system10 is connected to or communicable with the discharging channels 20 a,20 b. The extruding system 10 includes a mixing barrel 11 and aninjection outlet 12. The mixing barrel 11 is configured to mix thepolymeric material with the blowing agent to form the mixture, and theinjection outlet 12 is configured to extrude the mixture.

In some embodiments, the mixture includes a high molecular weightpolymer and a blowing agent. In some embodiments, the blowing agent is aphysical or chemical additive that releases gas during the heatingprocess, thereby forming pores in the thus-obtained foamed article. Insome embodiments, the blowing agent is a physical additive. In someembodiments, the blowing agent is a supercritical fluid (SM.

In some embodiments, the mixture accumulated at the mixing barrel 11 maybe injected from the injection outlet 12 into the discharging channels20 a, 20 b. In some embodiments, one discharging channel 20 acorresponds to one injection outlet 12. The mixture flows from oneextruding system 10 or one injection outlet 12 into one dischargingchannel 20 a. In some embodiments, one injection outlet 12 correspondsto several discharging channels 20 a, 20 b. In some embodiments, theextruding system 10 is configured to produce a plurality of portions ofthe mixture, wherein each portion of the mixture has a physicalcondition or property different from that of the other portions, andeach of the discharging channels 20 a, 20 b is configured to dischargedifferent portions of the mixture.

In some embodiments, the discharging channels 20 a, 20 b are connectedto or communicable with the injection outlet 12. In some embodiments,each of the discharging channels 20 a, 20 b is attached to the injectionoutlet 12. The number of the discharging channels 20 a, 20 b may beadjusted according to the property of the mixture. The dischargingchannels 20 a, 20 b are parallel to each other and arranged adjacent toeach other, In some embodiments, each discharging channel 20 a, 20 b mayaccommodate different amounts of the mixture injected from the injectionoutlet 12. The discharging channels 20 a, 20 b may discharge the sameamount or different amounts of the mixture into the molding device 30.In some embodiments, each of the discharging channels 20 a, 20 b mayoperate under different temperatures.

Each discharging channel 20 a, 20 b has an outlet 21 distal from theinjection outlet 12. In some embodiments, the outlets 21 can have widthsor diameters different from the widths or diameters of the other outlets21, and thus the outlets 21 can have different flow rates of themixture. In some embodiments, the outlets 21 can discharge differentamounts of the mixture. FIG. 1 illustrates two discharging channels 20a, 20 b corresponding to one molding device 30 for clarity andsimplicity, but such example is intended to be illustrative only, and isnot intended to be limiting to the embodiments. A person ordinarilyskilled in the art would readily understand that any suitable number ofthe discharging channels 20 a, 20 b may be utilized. Additionally, thedischarging channels 20 a, 20 b are illustrated as having at least onedifferent feature; this is intended to be illustrative and is notintended to limit the embodiments, as the discharging channels 20 a, 20b may have similar structures or different structures in order to meetthe desired functional capabilities.

The discharging channels 20 a, 20 b may be moved, extended, or fedsynchronously or separately. In some embodiments, the outlets 21 of thedischarging channels 20 a, 20 b may be extended into and be retractedfrom the molding device 30.

The number of the molding devices 30 may be adjusted according torequirements. In some embodiments, one molding device 30 corresponds tothe discharging channels 20 a, 20 b. The mixture can flow from theextruding system 10 into one molding device 30 through the dischargingchannels 20 a, 20 b. Further, FIG. 1 illustrates only one molding device30 for clarity and simplicity, but such example is intended to beillustrative only, and is not intended to be limiting to theembodiments. A person ordinarily skilled in the art would readilyunderstand that any suitable number of the molding devices 30 may beutilized, and all such combinations are fully intended to be includedwithin the scope of the embodiments.

In some embodiments, the discharging channels 20 a, 20 b are movable. Insome embodiments, the discharging channels 20 a, 20 b can movehorizontally, and then stop above one of the molding device 30 and alignwith the corresponding feeding ports 35 a, 35 b. After the alignment,the discharging channels 20 a, 20 b move toward the molding device 30,such that the discharging channels 20 a, 20 b engage with the moldingdevice 30. In some embodiments, the discharging channels 20 a, 20 b areengaged with openings 341 of the upper mold base 34 respectively. Afterthe engagement, the mixture is injected from the discharging channels 20a, 20 b into the molding device 30. After the injection, the dischargingchannels 20 a, 20 b withdraw from the molding device 30, and then theextruding system 10 and the discharging channels 20 a, 20 b may movetoward the next molding device 30.

The molding device 30 includes an upper mold base 34 and a mold underthe upper mold base 34. In some embodiments, the mold includes an uppermold 32 under the upper mold base 34, a lower mold 33 opposite to theupper mold 32, and a hollow space 31 defined by the upper mold 32 andlower mold 33.

In some embodiments, the hollow space 31 is defined by the upper mold 32and the lower mold 33. In some embodiments, the upper mold 32 and thelower mold 33 are complementary with and separable from each other. Thelower mold 33 includes a lower mold cavity, and the upper mold 32includes an upper mold cavity opposite to the lower mold cavity. In someembodiments, the hollow space 31 is formed by the upper mold cavity andthe lower mold cavity. FIG. 1 illustrates one mold including one hollowspace 31 for clarity and simplicity, but such example is intended to beillustrative only, and is not intended to be limiting to theembodiments. A person ordinarily skilled in the art would readilyunderstand that one mold may include several hollow spaces 31. Forexample, one mold may include two hollow spaces 31 defined by one uppermold 32 and one lower mold 33.

In some embodiments, a plurality of feeding ports 35 a, 35 bcorresponding to the discharging channels 20 a, 20 b are disposed in themolding device 30. In some embodiments, the feeding ports 35 a, 35 b aredisposed over the upper mold 32 or the lower mold 33 and arecommunicable with the hollow space 31, the upper mold cavity or thelower mold cavity. FIG. 1 illustrates two feeding ports 35 a, 35 bincluded in one mold for clarity and simplicity, but such example isintended to be illustrative only, and is not intended to be limiting tothe embodiments. A person ordinarily skilled in the art would readilyunderstand that one mold may include one or more feeding ports 35communicable with one or more hollow spaces 31.

The feeding port 35 is configured to dock the outlet 21. In someembodiments, several feeding ports 35 a, 35 b are disposed in themolding device 30 and configured to dock the corresponding outlets 21.In some embodiments, the discharging channels 20 a, 20 b are received bythe upper mold base 34. Each of the discharging channels 20 a, 20 b isat least partially surrounded by the upper mold base 34, and the outlets21 are docked to the feeding ports 35 a, 35 b. The mixture can betransported from the discharging channels 20 a, 20 b into the hollowspace 31 through the outlet 21 and the feeding ports 35 a, 35 b. In someembodiments, the feeding ports 35 a, 35 b can have different widths ordiameters. In some embodiments, the mixture is injected into the hollowspace 31 and then a foamed article is formed in the hollow space 31after a period of time.

In some embodiments, the upper mold base 34 includes openings 341configured to receive the corresponding discharging channels 20 a, 20 b.Each of the openings 341 extends through the upper mold base 34. Theupper mold base 34 may be mounted on the upper mold 32 by a screw, aclamp, a fastening means or the like. In some embodiments, the materialof the upper mold base 34 is the same as the material of the upper mold32. In some embodiments, a width of the upper mold base 34 is greaterthan that of the upper mold 32 or the lower mold 33. In someembodiments, the number of openings 341 corresponds to the number of thedischarging channels 20 a, 20 b.

In some embodiments, a length L of each of the discharging channels 20a, 20 b is related to some factors, such as a thickness H of the uppermold base 34, a clamping force for holding the molding device 30,properties of material for making the molding device 30, fluidity of theportion of the mixture, temperature of the portion of the mixture, orthe like. In some embodiments, the thickness H of the upper mold base 34is less than the length L of the discharging channels 20 a, 20 b.

In order to keep the fluidity and temperature of the mixture within apredetermined range, in some embodiments, the length L of each of thedischarging channels 20 a, 20 b is reduced as much as possible but isstill greater than the thickness H of the upper mold base 34.

In some embodiments, the injection-molding system 100 further includes acontrol system 60. The control system 60 is configured to control theextruding system 10, the discharging channels 20 a, 20 b, and themolding device 30. In some embodiments, the control system 60automatically controls the extruding system 10, the discharging channels20, and the molding devices 30 in real time.

In some embodiments, the control system 60 includes a central processor61 and a plurality of sensors 62 electrically connected to orcommunicable with the central processor 61. In some embodiments, thesensors 62 are placed throughout the injection-molding system 100 andconfigured to sense at least one processing condition (e.g., flow rateor viscosity of the mixture through the discharging channels 20 a, 20 b,an amount of the mixture discharged from the discharging channels 20 a,20 b, a pressure inside the hollow space 31, etc.) at a predeterminedposition of the injection-molding system 100. For example, at least onesensor 62 is installed at each outlet 21 for sensing the processingcondition at each outlet 21. In some embodiments, the sensor 62 isconfigured to detect the processing condition and transmit a signal ordata based on the processing condition detected to the central processor61 for further analysis.

In some embodiments, the control system 60 is configured to adjust themixing condition of the extruding system 10 and the extruding amount andtiming of the discharging channels 20 a, 20 b. The flow rates of themixture at the outlets 21 are adjustable. In some embodiments, the flowrates of the mixture at the outlets 21 can be adjusted automatically. Insome embodiments, the flow rate of the mixture at the outlet 21 can beadjusted based on parameters such as pressure inside the hollow space31, density of the mixture in the molding device 30, etc.

In some embodiments, one or more protrusions 36 are coupled with thehollow space 31 and disposed on an inner wall of the hollow space 31,and the foamed article formed in the hollow space 31 may have a groovecorresponding to the protrusion 36. The number of the protrusions 36 maybe adjusted according to requirements. In some embodiments, one or moregrooves are disposed on an inner wall of the hollow space 31, and thefoamed article formed in the hollow space 31 may have a protrusioncorresponding to the grooves. The number of the grooves or protrusions36 may be adjusted according to requirements, The number and location ofthe plurality of protrusions 36 and/or grooves are not particularlylimited; for example, the protrusions 36 or grooves can be arranged atthe inner sidewall of the hollow space 31 and separated from each other;however, the present invention is not limited thereto.

In some embodiments, the protrusion 36 or the groove is disposed at theinner top wall or the inner sidewall of the upper mold 32. In someembodiments, the feeding ports 35 a, 35 b and the protrusion 36 or thegroove are disposed on opposite sides of the hollow space 31; as anexample but not limitation, the feeding ports 35 a, 35 b are disposed atthe inner top wall of the upper mold 32, and the protrusion 36 or thegroove is disposed at the inner bottom wall of the lower mold 33. Insome embodiments, the feeding ports 35 a, 35 b are disposed at the innertop wall of the upper mold 32, and the protrusion 36 or the groove isdisposed at the inner sidewall of the lower mold 33. In sonicembodiments, the feeding ports 35 a, 35 b are disposed at the innersidewall of the upper mold 32, and the protrusion 36 or the groove isdisposed at the inner sidewall of the lower mold 33 and is located at aside opposite to the feeding ports 35 a, 35 b. In some embodiments, thefeeding ports 35 a, 35 b are distal from the protrusion 36 or thegroove.

FIG. 2 is a top cross-sectional view of the molding device 30. In someembodiments, as shown in FIG. 2, the protrusion 36 or the groove extendsacross the hollow space 31 from a top view. The position and width ofeach of the feeding ports 35 a, 35 b can be adjusted according toconfigurations of the protrusion 36 such as its position in the hollowspace 31, or the thickness, size or shape of the protrusion 36. Theposition and width of each of the feeding ports 35 a, 35 b can beadjusted according to a structural design of the mold cavity, theposition of the groove, physical properties of the foamed article, etc.

FIG. 3 is a top view of a foamed article formed by an injection-moldingsystem according to one embodiment of the present invention. In someembodiments, as shown in FIG. 3, different parts of the foamed article80 may have the same or different properties or configurations such asdensity, thickness, flexibility, strength, etc. The differences may beminor. In some embodiments, the foamed article 80 may be a wearabledevice. In some embodiments, the foamed article 80 is customizedaccording to user conditions or user requests.

In some embodiments, the foamed article 80 thus obtained may haveportions with different properties. In some embodiments, the mixture isinjected into the molding device 30 through two discharging channels 20a, 20 b, and the foamed article 80 thus formed includes a first portion81 and a second portion 82. The first portion 81 is formed by themixture injected from one discharging channel 20 a, and the secondportion 82 is formed by the mixture injected from the other dischargingchannel 20 b. In some embodiments, the groove 83 is disposed between thefirst portion 81 and the second portion 82. In some embodiments, thefoamed article 80 is divided into the first portion 81 and the secondportion 82 by the groove 83 from the top view.

The first portion 81 and second portion 82 of the foamed article 80 mayhave the same property or different properties or configurations such asdensity, thickness, flexibility, strength, etc. The properties andconfigurations of each portion depend on the feeding rate of themixture, the shape of the hollow space 31, and structural configurationof the protrusion 36 of the molding device 30. In some embodiments, thegroove 83 is formed on the foamed article 80 corresponding to theprotrusion 36.

In some embodiments, the foamed article 80 may have marks 84 a, 84 bcorresponding to the positions of the feeding ports 35 a, 35 b. In someembodiments, an outer surface of the foamed article 80 includes themarks 84 a, 84 b corresponding to the feeding ports 35 a, 35 b. Themarks 84 a, 84 b may be formed due to the pressure difference betweenthe hollow space 31 and the corresponding feeding ports 35 a, 35 b.

Each of the marks 84 a, 84 b may be circular or square in shape, but thedisclosure is not limited thereto. In some embodiments, the first mark84 a and the second mark 84 b are circular in shape. In someembodiments, the size and shape of each of the marks 84 a, 84 b isidentical to the corresponding feeding port 35. The mark 84 a, 84 b canbe a recess or a protrusion. In some embodiments, the mark 84 a, 84 b isslightly protruding. In some embodiments, the mark 84 a, 84 b is formedafter application of a shear or cutting force over the outer surface ofthe foamed article 80. The density of the mark 84 a, 84 b may bedifferent from that of the other portions of the foamed article 80. Themarks 84 a, 84 b may be same or different. The appearance of the mark 84a, 84 b depends on the width of the corresponding feeding port 35, theproperties of the material, etc.

In some embodiments, a first mark 84 a is disposed at the first portion81, and a second mark 84 b is disposed at the second portion 82. Thefirst mark 84 a is disposed distal from the second mark 84 b. In someembodiments, the first mark 84 a and the second mark 84 b are disposedalong a main central axis b-b′ of the foamed article 80. In someembodiments, the main central axis b-b′ extends along a longestdimension of the foamed article 80. In some embodiments, the first mark84 a and the second mark 84 b are disposed in a row along the longestdimension of the foamed article 80. In some embodiments, the first mark84 a and the second mark 84 b have same or different dimensions andshapes. In some embodiments, the first mark 84 a is larger than thesecond mark 84 b.

FIG. 4 is a cross-sectional view along a line a-a′ of FIG. 3. In someembodiments, referring to FIGS. 3 and 4, the foamed article 80 has agroove 83 corresponding to the protrusion 36 included in the hollowspace 31. In some embodiments, the first portion 81 and the secondportion 82 are separated by the groove 83 due to the inability of themixture injected to the first portion 81 to easily flow to the secondportion 82, and the inability of the mixture injected to the secondportion 82 to easily flow to the first portion 81. In some embodiments,a surface of the foamed article 80 has a pattern. The pattern may be asilky pattern. In some embodiments, the pattern is a shiny pattern.

FIGS. 5 to 10 are schematic diagrams of injection-molding systems invarious configurations. In some embodiments, as shown in FIG. 5, each ofthe discharging channels 20 a, 20 b corresponds to a molding device 30.The mixture can be extruded to each of the discharging channels 20 a, 20b through the injection outlet 12. In some embodiments, each of thedischarging channels 20 a, 20 b can discharge the same or differentamounts of the mixture. In some embodiments, the discharging channels 20a, 20 b have widths or diameters same as or different from those ofother discharging channels 20 a, 20 b. In some embodiments, thedischarging channels 20 a, 20 b have flow rates same as or differentfrom those of other discharging channels 20 a, 20 b. In someembodiments, since one extruding system 10 is required to supply themixture for several discharging channels 20 a, 20 b, the extrudingsystem 10 with a relatively higher extruding power or conveying speed isrequired in order to be capable of providing a sufficient amount of themixture for each of the molding devices 30 within a predetermined periodof time. In some embodiments, the number of discharging channels 20 a,20 b is the same as the number of molding devices 30. For example, asshown in FIG. 5, there are two discharging channels 20 a, 20 bcorresponding to two molding devices 30. FIG. 5 illustrates twodischarging channels 20 a, 20 b and two molding devices 30 for clarityand simplicity, but such example is intended to be illustrative only,and is not intended to be limiting, A person ordinarily skilled in theart would readily understand that any suitable numbers of thedischarging channels 20 a, 20 b and the molding devices 30 can beutilized, and all such combinations are fully intended to be includedwithin the scope of the embodiments.

In some embodiments, each of the hollow spaces 31 of the molding devices30 receives a same amount or different amounts of the mixture. In someembodiments, each of the hollow spaces 31 of the molding devices 30receives the mixture at the same time or at different times. Forexample, the discharging channel 20 a (on the left in FIG. 5) is closedby a valve or the like and thus no mixture can flow into the hollowspace 31 (on the left in FIG. 5) during a flowing of the mixture fromanother discharging channel 20 b (on the right in FIG. 5) into thehollow space 31 (on the right in FIG. 5).

In some embodiments, each of the molding devices 30 includes one or moreof the feeding ports 35 a, 35 b, 35 c. In some embodiments, moldingdevices 30 may have a same number or different numbers of the feedingports 35 a, 35 b, 35 c. For example, the molding device 30 (on the leftin FIG. 5) has two feeding ports 35 a, 35 b communicable with thecorresponding discharging channel 20 a, and another molding device 30(on the right in FIG. 5) has one feeding port 35 c communicable with thecorresponding discharging channel 20 b. In other words, one dischargingchannel 20 a, 20 b may correspond to several feeding ports 35 a, 35 b.

In some embodiments, the control system 60 controls the molding devices30 and the discharging channels 20 a, 20 b. In some embodiments, thecables 63 are electrically connected between the control system 60 andthe extruding system 10, the discharging channels 20 a, 20 b, and themolding devices 30. The cables 63 are configured to transmit the signalfrom the molding devices 30 to the extruding system 10 and thedischarging channels 20 a, 20 b.

In some embodiments, as shown in FIG. 6, several mixing barrels 11correspond to one injection outlet 12, and one injection outlet 12corresponds to several discharging channels 20 a, 20 b. In other words,several mixing barrels 11 are connected to or communicable with oneinjection outlet 12, and one injection outlet 12 is connected to orcommunicable with several discharging channels 20 a, 20 b. In someembodiments, the extruding systems 10 are configured to produce aplurality of portions of the mixture, wherein each portion of themixture has physical condition or property different from each other,and each of the discharging channels 20 a, 20 b is configured todischarge different portions of the mixture. FIG. 6 illustrates twomixing barrels 11 for clarity and simplicity, but such example isintended to be illustrative only, and is not intended to be limiting. Aperson ordinarily skilled in the art would readily understand that anysuitable number of the extruding systems 10 can be utilized, and allsuch combinations are fully intended to be included within the scope ofthe embodiments.

Compared to the embodiment of FIG. 5, the embodiment of FIG. 6 requiresa relatively lower extruding power or conveying speed, since each of themixing barrels 11 in the embodiment of FIG. 6 is only required to supplythe mixture for one of the discharging channels 20 a, 20 b.

In some embodiments, as shown in FIG. 7, one extruding system 10corresponds to several injection outlets 12, and several injectionoutlets 12 correspond to several discharging channels 20 a, 20 b. Inother words, one extruding system 10 is connected to or communicablewith several injection outlets 12, and several injection outlets 12 areconnected to or communicable with several discharging channels 20 a, 20b. FIG. 7 illustrates two injection outlets 12 for clarity andsimplicity, but such example is intended to be illustrative only, and isnot intended to be limiting. A person ordinarily skilled in the artwould readily understand that any suitable number of the injectionoutlets 12 can be utilized, and all such combinations are fully intendedto be included within the scope of the embodiments.

In some embodiments as shown in FIG. 8, each of the discharging channels20 a, 20 b, 20 c corresponds to one of several molding devices 30. Insome embodiments, the discharging channels 20 a, 20 b, 20 c are arrangedin a line, a row, a column, an arc, a curve or any other suitablearrangements. The molding devices 30 may be similar to each other ordifferent from each other. FIG. 8 illustrates two molding devices 30 forclarity and simplicity, but such example is intended to be illustrativeonly, and is not intended to be limiting. A person ordinarily skilled inthe art would readily understand that any suitable number of the moldingdevices 30 can be utilized, and all such combinations are fully intendedto be included within the scope of the embodiments.

In some embodiments, the molding devices 30 receive the mixture at thesame times or at different times. For example, the discharging channels20 a, 20 b (on the left and in the middle in FIG. 8) are closed by aflow rate controller or the like and thus no mixture can flow into thehollow spaces 31 of the molding device 30 (on the left in FIG. 8) duringthe flowing of the mixture from another discharging channel 20 c (on theright in FIG. 8) into the hollow space 31 of another mold (on the rightin FIG. 8).

In some embodiments, as shown in FIG. 9, the molding device 30 mayinclude several hollow spaces 31. In some embodiments, the hollow spaces31 of the molding device 30 are isolated from each other and are notcommunicable with each other. FIG. 9 illustrates the molding device 30including two hollow spaces 31 for clarity and simplicity, but suchexample is intended to be illustrative only, and is not intended to belimiting. Each of the molding devices 30 may correspond to one or moredischarging channels 20 a, 20 b. A person ordinarily skilled in the artwould readily understand that any suitable number of the hollow spaces31 can be utilized, and all such combinations are fully intended to beincluded within the scope of the embodiments.

In some embodiments, the hollow spaces 31 of the molding devices 30 havea same volume as each other or different volumes from each other. Forexample, a volume of the hollow space 31 (on the left in FIG. 9) isgreater than a volume of another hollow space 31 (in the middle in FIG.9). In some embodiments, each hollow space 31 may receive the mixture ina same amount or in different amounts. For example, the hollow space 31(on the left in FIG. 9) receives a larger amount of the mixture thananother hollow space 31 (in the middle in FIG. 9). In some embodiments,each hollow space 31 may receive the mixture at the same time or atdifferent times. For example, the discharging channels 20 a, 20 c (onthe left and right in FIG. 9) are closed by a flow rate controller orthe like and thus no mixture can flow into the hollow spaces 31 (on theleft and right in FIG. 9) during the flowing of the mixture from anotherdischarging channel 20 b (in the middle) into the another hollow space31 (in the middle in FIG. 9).

In some embodiments, the discharging channels 20 a, 20 b arecommunicable with different hollow spaces 31 of the molding device 30(on the left in FIG. 9). In sonic embodiments, each of the dischargingchannels 20 a, 20 b can discharge the same amount or different amountsof the mixture. In some embodiments, the discharging channels 20 a, 20 bhave widths or diameters that are same as or different from each other.In some embodiments, the discharging channels 20 a, 20 b have flow ratesthat are same as or different from flow rates of other dischargingchannels 20 a, 20 b. FIG. 9 illustrates the mixture being injected intoeach hollow spaces 31 of the molding device 30 through the correspondingdischarging channels 20 a, 20 b, 20 c for clarity and simplicity, butsuch example is intended to be illustrative only, and is not intended tobe limiting. A person ordinarily skilled in the art would readilyunderstand that any suitable number of the discharging channels 20 a, 20b, 20 c can be utilized, and all such combinations are fully intended tobe included within the scope of the embodiments.

In some embodiments, referring to FIG. 10, the extruding system 10 isconnected to or communicable with one discharging channel 20 and thedischarging channel 20 has a plurality of outlets 21. In someembodiments, the discharging channel 20 splits into a plurality ofbranches 201, and each of the branches 201 has an outlet 21 distal fromthe injection outlet 12. The number of the branches 201 may be adjustedaccording to the properties of the mixture. In some embodiments, eachbranch 201 may accommodate different amounts of the mixture injectedfrom the mixing barrel 11. The branches 201 may discharge the sameamount or different amounts of the mixture into the molding device 30.In some embodiments, each branch 201 may operate under a differenttemperature.

In some embodiments, the outlets 21 of the branches 201 can have widthsor diameters that are different from those of other outlets 21, and thusthe outlets 21 can have different flow rates. In some embodiments, theoutlets 21 can inject different amounts of the mixture. FIG. 10illustrates two branches 201 corresponding to one molding device 30 forclarity and simplicity, but such example is intended to be illustrativeonly, and is not intended to be limiting. A person ordinarily skilled inthe art would readily understand that any suitable number of thebranches 201 may be utilized. Additionally, the branches 201 areillustrated as having at least one different feature, which is intendedto be illustrative and is not intended to limit the embodiments, as thebranches 201 may have similar structures or different structures inorder to meet the desired functional capabilities.

FIGS. 11a to 11c are schematic diagrams showing the discharging channel20 in various configurations or states. In some embodiments, referringto FIGS. 11a to 11 c, the discharging channel 20 is in a taperedconfiguration. In some embodiments, the discharging channel 20 istapered toward the outlet 21, such that the discharging channel 20proximal to the outlet 21 has a width substantially less than thedischarging channel 20 distal to the outlet 21. For example, a diameterof the discharging channel 20 proximal to the outlet 21 is substantiallyless than a diameter of the discharging channel 20 distal to the outlet21.

In some embodiments, at least one of the plurality of dischargingchannels 20 further includes a flow rate controller 50. In someembodiments, each of the discharging channels 20 includes the flow ratecontroller 50, and the flow rates of the mixture at the correspondingoutlets 21 can he the same, slightly different, or significantlydifferent. In some embodiments, the flow rate controller 50 iscontrolled by the control system 60. The flow rate controller 50 may bean adjustable plug 51 disposed in the discharging channel 20. The plug51 is configured to adjust the flow rate of the mixture at the outlet21. In some embodiments, the plug 51 is movable relative to thedischarging channel 20. In some embodiments, the plug 51 is movabletoward and away from the outlet 21.

In some embodiments, the flow rates of the mixture at the outlets 21 canbe adjusted by changing the width or diameter of the outlet 21, theamount of the mixture extruded from the injection outlet 12, or theposition of the plug 51. In some embodiments, the flow rate of themixture at the outlet 21 may be first adjusted by changing the width ordiameter of the outlet 21 and/or the amount of the mixture extruded fromthe injection outlet 12, and then further adjusted by changing theposition of the plug 51.

In some embodiments, referring to FIG. 11a , the plug 51 is distal fromthe outlet 21. In some embodiments, referring to FIG. 11b , comparedwith FIG. 11 a, the plug 51 as shown in FIG. 11b is closer to the outlet21 but not in contact with the outlet 21, so that an amount of themixture discharged from the outlet 21 as shown in FIG. 11a issubstantially more than an amount of the mixture discharged from theoutlet 21 as shown in FIG. 11b . In some embodiments, the plug 51 isvery close to the outlet 21, such that only a small amount of themixture can be discharged from the outlet 21.

In some embodiments, referring to FIG. 11c , a portion of the plug 51blocks the outlet 21, such that the mixture cannot flow out of theoutlet 21. In other words, the plug 51 can serve as a valve to allow themixture to flow out from the outlet 21 (for example, as shown in FIGS.11a to 11c ) or to prevent the mixture from flowing out from the outlet21.

FIG. 12 is a schematic diagram of an injection-molding; system accordingto one embodiment of the present invention. In some embodiments,referring to FIG. 12, in order to maintain the temperature differencebetween the discharging channels 20 a, 20 b and the molding device 30,the injection-molding system further includes an insulator 70 disposedbetween the discharging channels 20 a, 20 b and the molding devices 30.In some embodiments, the insulator 70 is disposed between thedischarging channels 20 a, 20 b and the upper mold base 34. In someembodiments, the insulator 70 is disposed on the upper mold base 34. Insome embodiments, the insulator 70 is disposed between the outlet 21 andthe feeding ports 35 a, 35 b.

Each of the discharging channels 20 a, 20 b may extend into theinsulator 70 and is thereby partially surrounded by the insulator 70. Insome embodiments, the insulator 70 includes openings 71 configured toreceive the corresponding discharging channels 20 a, 20 b. The openings71 of the insulator 70 are aligned with the openings 341 of the uppermold base 34. Each of the openings 71 extends through the insulator 70.The insulator 70 may be mounted on the upper mold base 34, such as by ascrew. The insulator 70 may include a non-thermally conductive material,such as a fiberglass. The insulator 70 may be comprised entirely ofnon-metal materials. In some embodiments, the insulator 70 has a meltingpoint substantially greater than a temperature of the mixture flowingthrough the discharging channels 20 a, 20 b. In some embodiments, themelting point of the insulator 70 is substantially greater than 180° C.

In some embodiments, a width of the insulator 70 is less than that ofthe upper mold base 34. The thickness of the insulator 70 may be relatedto several factors, such as properties of materials for making themolding device 30 and the discharging channels 20 a, 20 b, temperaturesof the discharging channels 20 a, 20 b and the upper mold base 34, orthe like. In some embodiments, the thickness of the insulator 70 is lessthan the thickness H of the upper mold base 34.

In some embodiments, the temperature of each of the discharging channels20 a, 20 b is different from the temperature of the molding device 30.The temperature of each discharging channel 20 a, 20 b is greater thanthat of the molding device 30. In some embodiments, the temperature ofeach discharging channel 20 a, 20 b ranges between 150° C. and 200° C.,and a temperature of the molding device 30 may range between 20° C. and60° C.

In some embodiments, in order to maintain the temperature differencebetween the discharging channels 20 a, 20 b and the molding device 30and maintain the fluidity of the mixture, at least one of the pluralityof discharging channels 20 a, 20 b further includes a heater 72 disposedthereon. The heater 72 is configured to maintain or adjust thetemperature of the discharging channels 20 a, 20 b within apredetermined range. The heater 72 may keep the discharging channels 20a, 20 b within the same or different predetermined ranges. In someembodiments, each of the discharging channels 20 a, 20 b includes theheater 72 disposed thereon. In some embodiments, each of the dischargingchannels 20 a, 20 b includes the heater 72 disposed around the outlet21. In some embodiments, the heaters 72 may enter the openings 71 andthe openings 341 together with the corresponding discharging channels 20a, 20 b when the discharging channels 20 a, 20 b are engaged with themolding device 30. The positions and number of the heaters 72 may beadjusted according to requirements, and are not particularly limited.Each of the discharging channels 20 a, 20 b may include a differentnumber of heaters 72 or no heater 72.

In some embodiments, in order to maintain the fluidity of the mixture,the molding device 30 further includes a heater 73 configured tomaintain the temperature of the feeding ports 35 a, 35 b within apredetermined range. In some embodiments, the heater 73 is disposed inthe upper mold base 34 or the upper mold 32. In some embodiments, theheater 73 is disposed adjacent to the feeding ports 35 a, 35 b. Thepositions and number of the heaters 73 may be adjusted according torequirements, and are not particularly limited. In some embodiments, thefeeding ports 35 a, 35 b can be heated to a predetermined temperature(e.g., 200° C. or above) by the heater 73 during flowing of the mixturefrom the discharging channels 20 a, 20 b into the molding device 30, andthen the feeding ports 35 a, 35 b can be instantly cooled down to apredetermined temperature (e.g., 50° C. or lower) when the flowing ofthe mixture is completed. In some embodiments, the feeding ports 35 a,35 b are cooled down when the discharging channels 20 a, 20 b arewithdrawn from the molding device 30. In some embodiments, such instantcooling can be implemented by turning off the heater 73 or turning on acooling member disposed adjacent to the feeding port 35. Each of themolding devices 30 can include different numbers of heaters 73 or maynot include any heater. In some embodiments, the injection-moldingsystem includes the extruding system 10, the discharging channels 20 a,20 b, and a single molding device 30, wherein the molding device 30includes the heater 73 configured to adjust the temperature of thefeeding port 35. In some embodiments, each of the feeding ports 35 a, 35b includes the heater 73 disposed thereon.

In some embodiments, the control system 60 further electrically controlsthe insulator 70, the heaters 72 of the discharging channels 20 a, 20 b,and the heaters 73 of the molding devices 30 in real time. In someembodiments, the control system 60 controls the discharging channels 20a, 20 b to be connected to the molding devices 30, and controls theheaters 72 of the discharging channels 20 a, 20 b or the heaters 73 ofthe molding device 30 to heat the discharging channels 20 a, 20 b, theoutlets 21 or the feeding ports 35 a, 35 b to their own predeterminedtemperature or maintain the discharging channels 20 a, 20 b, the outlets21 or the feeding ports 35 a, 35 b at their own predeterminedtemperature.

FIG. 13 is a schematic diagram of an injection-molding system accordingto one embodiment of the present invention. In some embodiments,referring to FIG. 13, the injection-molding system further includes asupporting unit 40 configured to facilitate an engagement of thedischarging channels 20 a, 20 b to each of the plurality of moldingdevices 30. The supporting unit 40 can be disposed at any suitableposition in the injection-molding system 200. In some embodiments, thesupporting unit 40 is configured to support the discharging channels 20a, 20 b. In some embodiments, the supporting unit 40 is used to preventseparation of the discharging channels 20 a, 20 b and the molding device30 during the injection of the mixture. In some embodiments, the controlsystem 60 controls the supporting unit 40 in real time.

FIG. 14 is a schematic diagram of a part of the injection-molding systemaccording to one embodiment of the present invention. In someembodiments, referring to FIG. 14, the supporting device 40 includesfirst and second elements 41, 42 configured to engage with each other,wherein the first element 41 protrudes from the extruding system 10 orthe discharging channel 20, and the second element 42 is disposed oneach of the plurality of molding devices 30, but the disclosure is notlimited thereto. In some embodiments, the first and second elements, 41,42 can be clamped to each other; for example, the second element 42 canbe configured to receive the first element 41. In some embodiments, thefirst element 41 is disposed on the discharging channel 20, and thesecond element 42 is disposed on each molding device 30. In someembodiments, the second element 42 is disposed on the upper mold base 34of the molding device 30. In some embodiments, the first element 41 is apart of the extruding system 10 or the discharging channel 20, while thesecond element 42 is a part of the molding device 30. In someembodiments, the first element 41 is a part of the extruding system 10and disposed adjacent to the discharging channels 20 a, 20 b, and thesecond element 42 is disposed above or facing toward the upper mold base34 of the molding device 30. In some embodiments, the first element 41and the second element 42 can engage with each other, thereby tightlyengaging the discharging channels 20 a, 20 b with the upper mold base 34of the molding device 30.

In some embodiments, in order to prevent separation of the extrudingsystem 10 and the molding device 30 during the injection of the mixture,the engaged first element 41 is subjected to a force to against thesecond element 42. The force may be equal to or greater than athreshold. The threshold may be adjusted according to the pressure inthe hollow space 31 and the diameter of the outlet 21, or according toother factors.

The position and number of the first elements 41 may be adjustedaccording to requirements, and are not particularly limited. Theposition and number of the second elements 42 may also be adjustedaccording to requirements, and are not particularly limited. In someembodiments, the position and number of the second elements 42correspond to the position and number of the first elements 41. In anembodiment, the first element 41 can be disposed at any suitableposition on the discharging channel 20, and the second element 42 can bedisposed at any suitable position on the molding device 30. In someembodiments, the second element 42 is disposed above the upper mold 32.

FIG. 15 is a schematic diagram of a portion of the injection-moldingsystem according to one embodiment of the present invention. In someembodiments, referring to FIG. 15, the supporting unit 40 can be ineither of two states, a locked state and an unlocked state. In theunlocked state, the first element 41 enters the corresponding secondelement 42 but has not yet been locked with the second element 42. Inother words, the first element 41 can still be withdrawn from the secondelement 42 when the supporting unit 40 is in the unlocked state. In thelocked state, the first element 41 enters and locks with thecorresponding second element 42, such that the first element 41 cannotbe withdrawn from the second element 42. FIG. 11 illustrates thesupporting unit 40 in the locked state. The supporting unit 40 can beoperated and controlled manually or automatically. The supporting unit40 can be switched between the two states manually or automatically.

In some embodiments, the first element 41 is rotatably fixed to theextruding system 10. In some embodiments, the first element 41 includesan elongated portion 411 and an arm portion 412. The elongated portion411 and the arm portion 412 are rotatable in a direction indicated by anarrow A. The elongated portion 411 is fixed to the extruding system 10and extends in a first direction Z toward the upper mold 32. The armportion 412 is coupled to the elongated portion 411 and extends in asecond direction X substantially orthogonal to the first direction Z orin a third direction Y substantially orthogonal to the first directionZ. In some embodiments, the first element 41 has an inverted T shape.After the first element 41 enters the second element 42, the supportingunit 40 is shifted from the unlocked state to the locked state byrotation of the arm portion 412 of the first element 41. In someembodiments, the first element 41 is locked with the second element 42by rotating the arm portion 412 of the first element 41 with about 90degrees. FIG. 14 illustrates the arm portion 412 locked with the secondelement 42 after rotating the arm portion 412 with about 90 degrees. Asa result, the supporting unit 40 is in the locked state, and thedischarging channel 20 is tightly engaged with the molding device 30,and thus the injection of the mixture from the extruding system 10 andthe discharging channel 20 to the molding device 30 can begin.

FIG. 16 is a schematic diagram of an injection-molding system accordingto one embodiment of the present invention. Referring to FIG. 16, insome embodiments, the molding device 30 of an injection-molding systemfurther includes a sealing element 39 configured to tightly dock theupper mold 32 to the lower mold 33. In some embodiments, the sealingelement 39 is disposed below the lower mold 33 and provides a forcetoward the discharging channels 20 a, 20 b. In some embodiments, a firstforce toward the molding device 30 is generated during the injecting ofthe mixture, and the sealing element 39 provides a second force againstthe first force. In some embodiments, the sealing element 39 is disposedbetween the upper mold 32 and the lower mold 33. In some embodiments,the control system 60 controls the sealing element 39 in real time. Insome embodiments, a seal ring is disposed between the upper mold 32 andthe lower mold 33, or between the upper mold base 34 and the upper mold32. In some embodiments, the seal ring is disposed around all sides ofthe molding device 30.

FIG. 17 is a top cross-sectional view of a part of the injection-moldingsystem according to one embodiment of the present invention. FIG. 18 isa schematic diagram of a part of the injection-molding system accordingto one embodiment of the present invention. After injection of themixture into the molding device 30, the discharging channels 20 a, 20 bare disengaged from the feeding ports 35 a, 35 b, at which point themixture in the molding device 30 may overflow out of the molding device30 from the feeding ports 35 a, 35 b and the opening 341. In someembodiments, referring to FIGS. 17 and 18, the injection-molding systemfurther includes a cover 50 configured to prevent the overflow of themixture. In some embodiments, the cover 50 is configured to stop themixture from overflowing from the feeding ports 35 a, 35 b of the uppermold 32. In some embodiments, the cover 50 is configured to cover thefeeding ports 35 a, 35 b of the upper mold 32. In some embodiments, thecover 50 is configured to stop the mixture from overflowing from thefeeding ports 35 a, 35 b of the upper mold 32 and the opening 341 of theupper mold base 34. In some embodiments, the cover 50 is configured tocover the feeding ports 35 a, 35 b of the upper mold 32 and the opening341 of the upper mold base 34. In some embodiments, the cover 50 ismoved to cover the feeding ports 35 a, 35 b immediately after thedischarging channel 20 is withdrawn from the upper mold base 34.

In some embodiments, the cover 50 is attached to the molding device 30.The cover 50 may be an individual element or module disposed between themolding devices 30 and the discharging channels 20 a, 20 b. In someembodiments, the cover 50 is attached to the upper mold base 34. Thenumber of covers 50 is not particularly limited. In some embodiments,the number corresponds to the number of the openings 341 of the uppermold base 34 or the number of the feeding ports 35 a, 35 b.

FIGS. 19 and 20 are schematic diagrams of the cover 50 in variousconfigurations or states. In some embodiments, referring to FIGS. 19 and20, the cover 50 is configured to move between a first position 51 and asecond position 52. At the first position 51, referring to FIGS. 18 and19, the cover 50 is away from the opening 341 and the correspondingfeeding port 35 a, 35 b, and the corresponding discharging channel 20 a,20 b can engage with the corresponding feeding port 35 a, 35 b. At thesecond position 52, referring to FIGS. 17 and 20, the cover 50 coversthe corresponding opening 341 and the corresponding feeding port 35 a,35 b, and the corresponding discharging channel 20 a, 20 b cannot engagewith the corresponding feeding port 35 a, 35 b. In some embodiments, thecover 50 can be operated manually or automatically. In some embodiments,movement of the cover 50 can be controlled manually or automatically bythe control system 60 in real time. In some embodiments, the cover 50 ismoved from the first position 51 to the second position 52 to cover thefeeding port 35 a, 35 b immediately after the discharging channel 20 a,20 b is withdrawn from the upper mold base 34.

FIG. 21 is a schematic diagram of an injection-molding system accordingto one embodiment of the present invention. In some embodiments,referring to FIG. 21, the injection-molding system includes an extrudingsystem 10, a plurality of discharging channels 20 a, 20 b and a moldingdevice 30. The injection-molding system further includes a supportingdevice 40, covers 50, a control system 60, an insulator 70, and heaters72. 73. Each of the molding devices 30 includes a hollow space 31, anupper mold 32, a lower mold 33, an upper mold base 34, and a feedingport 35. The molding device 30 may further include, for example, asealing element 39, and/or a protrusion 36 as described above or shownin FIGS. 1 and 16.

In the present disclosure, an injection molding method is disclosed. Themethod includes a number of operations and the description andillustrations are not deemed as a limitation of the sequence of theoperations. FIG. 22 is a flowchart illustrating an injection moldingmethod according to one embodiment of the present invention. In someembodiments, as shown in FIG. 22, the method of injection molding 900includes the following steps.

Step 901 includes providing an extruding system configured to produce amixture of a polymeric material and a blowing agent, a first dischargingchannel, a second discharging channel, and a molding device including ahollow space, a first feeding port and a second feeding port. The firstdischarging channel is communicable with the extruding system andincludes a first outlet disposed distal from the extruding system, thesecond discharging channel is communicable with the extruding system andincludes a second outlet disposed distal from the extruding system, andthe first feeding port and the second feeding port are communicable withthe hollow space and engageable with the first outlet and the secondoutlet, respectively.

Step 902 includes engaging the first outlet with the first feeding port.

Step 903 includes engaging the second outlet with the second feedingport.

Step 904 includes injecting a first amount of the mixture into thehollow space through the first outlet and the first feeding port.

Step 905 includes injecting a second amount of the mixture into thehollow space through the second outlet and the second feeding port.

The method 900 is not limited to the above-mentioned embodiments. Insome embodiments, the method of injection molding 900 uses any of theabove-mentioned injection-molding systems as shown in FIGS. 1 to 21.

FIGS. 23 to 27 are schematic diagrams illustrating exemplary operationsfor method of injection molding according to one embodiment of thepresent disclosure. In some embodiments, referring to FIG. 23, theinjection molding method 900 includes step 901, which includes providingan extruding system 10 configured to produce a mixture of a polymer anda blowing agent, a first discharging channel 20 a, a second dischargingchannel 20 b, and a molding device 30 including a hollow space 31, afirst feeding port 35 a and a second feeding port 35 b. The firstdischarging channel 20 a is communicable with the extruding system 10and includes a first outlet 21 disposed distal from the extruding system10, and the second discharging channel 20 b is communicable with theextruding system 10 and includes a second outlet 21 disposed distal fromthe extruding system 10, and the first feeding port 35 a and the secondfeeding port 35 b are communicable with the hollow space 31 andengageable with the first outlet 21 and the second outlet 22,respectively.

In some embodiments, the upper mold 32 is sealed to the correspondinglower mold 33 by the sealing element 39.

In some embodiments, the supporting unit 40 is in an unlocked state. Insome embodiments, before the mixture is injected into the hollow space31. the covers 50 are disposed at the second position 52 to cover thefirst feeding port 35 a and the second feeding port 35 b.

In some embodiments, a temperature difference is provided between thefirst discharging channel 20 a and the second discharging channel 20 b.In some embodiments, a temperature difference is provided between themolding device 30 and the first and second discharging channels 20 a, 20b. In some embodiments, referring to FIG. 23, the heaters 72 disposed onthe first and second discharging channels 20 a, 20 b heat the first andsecond discharging channels 20 a, 20 b to predetermined temperatures. Insome embodiments, the heaters 73 disposed in the upper mold 32 heat thefirst feeding port 35a and the second feeding port 35 b to predeterminedtemperatures.

In some embodiments, at the beginning of step 901, the extruding system10 and the discharging channels 20 a, 20 b are distal from the moldingdevice 30.

In some embodiments, the method 900 includes step 902, which includesengaging the first outlet 21 of the first discharging channel 20 a withthe first feeding port 35 a.

Referring to FIG. 24, before the engagement of the first outlet 21 withthe first feeding port 35 of the molding device 30, the method 900includes moving the first discharging channel 20 a and the seconddischarging channel 20 b toward the molding device 30. In someembodiments, the first and second discharging channels 20 a, 20 b aremoved horizontally to the first position above the molding device 30. Atthe first position, the discharging channels 20 a, 20 b are aligned withthe corresponding openings 341 of the upper mold base 34 of the moldingdevice 30. In some embodiments, a distance between the first outlet 21and the upper surface of the upper mold base 34 is greater than 0.

In some embodiments, the method 900 includes step 903, which includesengaging the second outlet 21 of the second discharging channel 20 bwith the second feeding port 35 b. In some embodiments, the engagementof the first outlet 21 with the first feeding port 35 a and theengagement of the second outlet 21 with the second feeding port 35 b areimplemented simultaneously.

Referring to FIG. 25, after the vertical alignment of the first andsecond discharging channels 20 a, 20 b with the corresponding openings341, the first and second discharging channels 20 a, 20 b are movedtoward the molding device 30 to be received by the correspondingopenings 341 of the upper mold base 34, and then the first and secondoutlets 21 are docked to the corresponding first feeding ports 35 a, 35b. In some embodiments, the first and second discharging channels 20 a,20 b are moved vertically toward the molding device 30 to be received bythe corresponding openings 341 of the upper mold base 34.

After the first outlet 21 is docked to the first feeding ports 35 a, thefirst outlet 21 and the corresponding first feeding port 35a form a flowpath of the mixture, such that the discharging channel 20 a iscommunicable with the hollow space 31 through the first feeding port 35a. Similarity, after the second outlet 21 is docked to the secondfeeding port 35 b, the second outlet 21 and the corresponding secondfeeding port 35 b form another flow path of the mixture, such that thedischarging channel 20 b is communicable with the hollow space 31through the second feeding port 35 b. The outlets 21 must be tightlyengaged with the corresponding first and second feeding ports 35 a, 35 bin order to prevent the mixture from leaking out of the molding device30.

In some embodiments, when the mixture is ready to be injected by theextruding system 10, the first and second discharging channels 20 a, 20b are aligned with the molding device 30 and the cover 50 of the moldingdevice 30 is slid from the second position 52 to the first position 51.After the movement of the cover 50 from the second position 52 to thefirst position 51, the first and second outlets 21 can engage with thecorresponding first and second feeding ports 35 a, 35 b. After theengagement of the first outlet 21 and the first feeding port 35 a, andthe engagement of the second outlet 21 and the second feeding port 35 b,the injection begins. The cover 50 remains at the first position 51during the injection of the mixture.

In some embodiments, the method 900 further includes securing thedischarging channels 20 a, 20 b to the molding device 30 by shifting thesupporting unit 40 to the locked state, such as rotating a first element41 of the supporting device 40 relative to and within a second element42 of the supporting device 40 while engaging the outlet 21 with thefirst feeding port 35 a. In some embodiments, when the first and secondoutlets 21 are docked to the first and second feeding ports 35 a, 35 b,the first element 41 enters the second element 42 and then locks withthe second element 42.

In some embodiments, the heaters 72 heat the first and seconddischarging channels 20 a, 20 b to keep the temperature of thedischarging channels 20 a, 20 b within predetermined ranges. In someembodiments, the heaters 73 heat the first and second feeding ports 35a, 35 b to maintain the temperature of the first and second feedingports 35 a, 35 b within the predetermined ranges.

In some embodiments, referring to FIG. 26, the method 900 includes step904, which includes injecting a first amount of the mixture M1 into thehollow space 31 through the first outlet 21 and the first feeding port35 a. In some embodiments, the first discharging channel 20 a is atleast partially surrounded by the molding device 30 during the injectionof the first amount of the mixture M1. In some embodiments, the processof injecting the first amount of the mixture M1 into the hollow space 31lasts only 0.5 to 1 second.

In some embodiments, the method 900 includes step 905, which includesinjecting a second amount of the mixture M2 into the hollow space 31through the second outlet 21 and the second feeding port 35 b. In someembodiments, the second discharging channel 20 b is at least partiallysurrounded by the molding device 30 during the injection of the secondamount of the mixture M2. In some embodiments, the process of injectingthe second amount of the mixture M2 into the hollow space 31 lasts only0.5 to 1 second.

In some embodiments, the injection of the first amount of the mixture M1and the injection of the second amount of the mixture M2 are implementedsimultaneously. In some embodiments, a duration for injecting the firstamount of the mixture M1 is equal to a duration for injecting the secondamount of the mixture M2.

In some embodiments, a force is provided by the supporting device 40 toprevent the separation of the extruding system 10 from the moldingdevice 30. In some embodiments, in step 904 and step 905, when themixture is injected from the first and second outlets 21 into themolding device 30, the molding device 30 may generate a reaction forceopposite to an injection direction, and the reaction force may betransmitted to the first and second discharging channels 20 a, 20 b andthe extruding system 10, so that the first and second dischargingchannels 20 a, 20 b tend to separate from the molding device 30. In someembodiments, the supporting unit 40 provides support against thereaction force opposite to the injection direction.

In some embodiments, during the process of injection, the temperaturesof the first and second discharging channels 20 a, 20 b are greater thanthat of the molding device 30. In some embodiments, the temperaturedifference is maintained using the insulator 70 and the heaters 72, 73.

In some embodiments, the method 900 further includes forming a foamedarticle 80 in the hollow space 31 after step 904 and step 905. Thefoamed article 80 includes a first portion 81 formed by the first amountof the mixture M1 and a second portion 82 formed by the second amount ofthe mixture M2. In some embodiments, the first portion 81 and the secondportion 82 are disposed at the two opposite sides of a groovecorresponding to the protrusion 36.

In some embodiments, the foamed article 80 further includes a first mark84 a and a second mark 84 b corresponding to the first feeding port 35 aand the second feeding port 35 b, respectively. In some embodiments, thefirst mark 84 a is disposed in the first portion 81 and the second mark84 b is disposed in the second portion 82.

In some embodiments, the method 900 further includes disengaging thefirst outlet 21 from the first feeding port 35 a. In some embodiments,the method further includes disengaging the second outlet 21 from thesecond feeding port 35 b. In some embodiments, the disengagement of thefirst outlet 21 from the first feeding port 35 a and the disengagementof the second outlet 21 from the second feeding port 35 b areimplemented simultaneously. In some embodiments, after the injection ofthe first amount and the second amount of the mixtures M1, M2 into thehollow space 31, the first and second discharging channels 20 a, 20 bare disengaged from and moved away from the molding device 30.

In some embodiments, before the disengaging of the first outlet 21 fromthe first feeding port 35 a and the disengaging of the second outlet 21from the second feeding port 35 b, the supporting unit 40 is shifted tothe unlocked state. In some embodiments, the supporting unit 40 isshifted from the locked state to the unlocked state by rotating a firstelement 41 of the supporting device 40 relative to and within a secondelement 42 of the supporting device 40 to unlock the discharging channel20 from the molding device 30. In some embodiments, during thedisengagement of the first and second outlets 21 from the first andsecond feeding ports 35 a, 35 b, the first element 41 is unlocked fromthe second element 42 and is then pulled away from the second element42.

In some embodiments, the method 900 further includes covering the firstand second feeding port 35 a, 35 b during or after the disengagement ofthe first and second outlets 21 from the first and second feeding ports35 a, 35 b, respectively. When the first and second outlets 21 areseparated from the first and second feeding port 35 a, 35 b, each of thecovers 50 immediately slides from the first position 51 to the secondposition 52, so that the mixture in the molding device 30 does notoverflow from the first and second feeding ports 35 a, 35 b.

In some embodiments, the heaters 73 of the molding device 30 stopheating the first and second feeding ports 35 a, 35 b after injecting afirst and second amount of mixtures M1, M2 into the hollow space 31. Insome embodiments, the heaters 72 keep heating the first and seconddischarging channels 20 a, 20 b.

In the above-mentioned Step 901 to Step 905, the control system 60automatically controls the extruding system 10, the first and seconddischarging channels 20 a, 20 b, the molding devices 30, the supportingdevice 40, the covers 50, the insulator 70, and the heaters 72, 73 inreal time. In some embodiments, the control system 60 controls movementof the extruding system 10. In some embodiments, the control system 60controls movement of the first and second discharging channels 20 a, 20b.

The method 900 is not limited to the above-mentioned embodiments. Insome embodiments, the method of injection molding 900 uses any of theabove-mentioned molding devices as shown in FIGS. 1 to 21.

The foregoing outlines features of several embodiments so that thoseskilled in the art may better understand the aspects of the presentdisclosure. Those skilled in the art should appreciate that they mayreadily use the present disclosure as a basis for designing or modifyingother processes and structures for carrying out the same purposes and/orachieving the same advantages of the embodiments introduced herein.Those skilled in the art should also realize that such equivalentconstructions do not depart from the spirit and scope of the presentdisclosure, and that they may make various changes, substitutions, andalterations herein without departing from the spirit and scope of thepresent disclosure.

Moreover, the scope of the present application is not intended to belimited to the particular embodiments of the process, machine,manufacture, composition of matter, means, methods and steps describedin the specification. As one of ordinary skill in the art will readilyappreciate from the disclosure of the present invention, processes,machines, manufacture, compositions of matter, means, methods, or steps,presently existing or later to be developed, that perform substantiallythe same function or achieve substantially the same result as thecorresponding embodiments described herein, may be utilized according tothe present invention. Accordingly, the appended. claims are intended toinclude within their scope such processes, machines, manufacture,compositions of matter, means, methods and steps.

What is claimed is:
 1. An injection molding method, comprising:providing an extruding system configured to produce a mixture of apolymeric material and a blowing agent, a first discharging channel, asecond discharging channel, and a molding device including a hollowspace, a first feeding port and a second feeding port, wherein the firstdischarging channel is communicable with the extruding system andincludes a first outlet disposed distal from the extruding system, thesecond discharging channel is communicable with the extruding system andincludes a second outlet disposed distal from the extruding system, andthe first feeding port and the second feeding port are communicable withthe hollow space and respectively engageable with the first outlet andthe second outlet; engaging the first outlet with the first feedingport; engaging the second outlet with the second feeding port; injectinga first amount of the mixture into the hollow space through the firstoutlet and the first feeding port; and injecting a second amount of themixture into the hollow space through the second outlet and the secondfeeding port.
 2. The method of claim 1, further comprising moving thefirst discharging channel and the second discharging channel toward themolding device before the engagement of the first outlet with the firstfeeding port.
 3. The method of claim 1, further comprising securing atleast one of the first discharging channel and the second dischargingchannel to the molding device by engaging a first element of asupporting device relative to a second element of the supporting device,wherein the first element protrudes from the extruding system, and thesecond element is disposed on the molding device.
 4. The method of claim3, wherein the first element enters the second element and then lockswith the second element.
 5. The method of claim 3, wherein a force isprovided by the supporting device after the engagement to prevent thefirst discharging channel or the second discharging channel separatingfrom the molding device.
 6. The method of claim 3, wherein theengagement of the first element to the second element includes rotatingthe first element relative to and within the second element.
 7. Themethod of claim 6, wherein the at least one of the first dischargingchannel and the second discharging channel is secured to the moldingdevice by rotating an elongated portion and an arm portion of the firstelement of the supporting device, the elongated portion is fixed to theextruding system and extends in a first direction toward the moldingdevice, and the arm portion is coupled to the elongated portion andextends in a second direction different from the first direction.
 8. Themethod of claim 6, wherein the second direction is substantiallyorthogonal to the first direction.
 9. The method of claim 1, wherein theengagement of the first outlet with the first feeding port and theengagement of the second outlet with the second feeding port areimplemented simultaneously.
 10. The method of claim 1, wherein theinjection of the first amount of the mixture and the injection of thesecond amount of the mixture are implemented simultaneously.
 11. Themethod of claim 1, wherein a duration for injecting the first amount ofthe mixture is equal to a duration for injecting the second amount ofthe mixture.
 12. The method of claim 1, further comprising forming afoamed article in the hollow space, wherein the foamed article includesa first mark and a second mark corresponding to the first feeding portand the second feeding port, respectively.
 13. The method of claim 1,wherein the first amount of the mixture is different from the secondamount of the mixture.
 14. The method of claim 1, further comprisingextending the first discharging channel into the molding device to atleast partially surround the first discharging channel by the moldingdevice during the injection of the first amount of the mixture.
 15. Themethod of claim 1, wherein the injection of the first amount of themixture into the hollow space lasts for 0.5 to 1 second.
 16. The methodof claim 1, further comprising covering the first feeding port after thefirst amount of the mixture is injected into the hollow space throughthe first outlet and the first feeding port and retracting the firstdischarging channel from the molding device.
 17. The method of claim 1,wherein a temperature of the first discharging channel is substantiallygreater than a temperature of the molding device, and a temperature ofthe second discharging channel is substantially greater than thetemperature of the molding device.
 18. The method of claim 17, furthercomprising disposing an insulator over the molding device to separatethe first discharging channel from the molding device and separate thesecond discharging channel from the molding device.
 19. The method ofclaim 18, wherein the first discharging channel and the seconddischarging channel are partially surrounded by the insulator after thefirst outlet is engaged with the first feeding port and the secondoutlet is engaged with the second feeding port.
 20. The method of claim18, wherein the insulator is disposed between the first dischargingchannel and the molding device, or between the second dischargingchannel and the molding device.